Wire ropes deteriorate during operation and need inspection throughout their service life for safety of personnel and operations, economic and safe extension of rope life, and satisfying regulatory agency requirements.
Non-destructive testing of wire ropes can be provided with the wire rope tester INTROS. The INTROS is a dual-function instrument, i.e. it simultaneously detects Localized Flaws (LFs) and measures Loss of Metallic cross-sectional Area (LMA). LFs normally mean broken wires, which usually caused by metal fatigue, while LMA is typically caused by external and internal corrosion and abrasion.
The INTROS includes the basic unit (data logger) and the magnetic head connected with cable 5 or 8 m length. The magnetic head scans the rope along its working length, identifying internal and external defects. Size of the magnetic head is chosen according to the size of rope. Signals from defects are stored in the data logger and can be simultaneously shown on the unit display. Using software Wintros signals in the form of LF and LMA traces are downloaded to computer for analysis.
The INTROS operates magnetic flux leakage (MFL) principle, and is power supplied with rechargeable batteries. The magnetic head contains powerful rare-earth magnets to saturate the rope. Measuring system contains Hall generator and/or coils. Grease, paint, dirt or plastic sealing material, inspection speed does not affect results of inspection. The instrument is ruggedly designed, specially protected according to IP65 requirements, and can be used even in explosive environment, at ambient temperature -10° to +50°C. Carefully designed INTROS is smaller and lighter than competing instruments.
Practically application of the INTROS is unlimited: on-shore and off-shore, above ground and underground. The instrument is used for inspection of ropes of mine winders, cranes, elevators, aerial cableways, suspended bridges, guyed flares, TV towers, OHTL, etc.
The INTROS meets requirements of international standards like ASTM E1571, EN 12927, ISO 4309, and IMCA SEL 023.
The basic unit is important part of wire rope tester INTROS. It supplies the whole instrument with electricity, controls the instrument, shows measuring data on-line and stores them for further downloading. The basic unit is compatible with each magnetic head. Connection with magnetic head is provided with connecting cable 5 or 8 m length. Connecting cable delivered with magnetic head.
Magnetic heads for inspection of ropes up to 64 mm diameter have one-piece construction. They contain 2 flaps on hinge, and can be attached on to the rope under test and latched by the inspector manually. Rope is centered for better results with plastic liners installed into the magnetic head. In case with bigger ropes which are tested with magnetic heads MH 60-85, MH 80-120, and MH 100-150 magnetic attraction to the rope is much bigger. Installation technology for these magnetic heads is different. Their flaps are installed on to the rope one by one and connected thereafter with the cable. The MH 80-120 and MH 100-150 are also equipped with special roller frame for the installation, alignment on the rope, and moving along the rope.
|Type of Magnetic Head||Appropriate rope size|
|MH 6-24||Diameter 6-24 mm|
|MH 6-24F||Diameter 6-24 mm|
|MB 8-24||Diameter 8-24 mm|
|MH 20-40||Diameter 20-40 mm|
|MH 24-64||Diameter 24-64 mm|
|MH 24-64M3||Diameter 24-64 mm|
|MH 40-64||Diameter 40-64 mm|
|MH 40-64||Diameter 40-64 mm|
|MH 60-85||Diameter 60-85 mm|
|MH 80-120||Diameter 80-120 mm|
|MH 100-150||Diameter 100-150 mm|
|MH 124||Flat 20 x 124 mm|
|MH 124R||Rubber flat 30 x 124 mm|
|MH 233||Flat 38 x 233 mm|
|MH 233R||Rubber flat 35 x 233 mm|
|MH 450R||Rubber flat 24 x 450 mm|
During inspection of the rope basic unit INTROS stores data for further downloading, analysis, and printing inspection report. This function is possible using the software WINTROS. Besides, it is possible to show test data in form of LMA and LF traces on-line on the computer screen. For this purpose software WINTROS-RTV is used.
INTROS-AUTO is a successor of widely used wire rope tester INTROS.
INTROS-AUTO designed for non-destructive inspection of wire ropes with automatic data interpretation. Automatic interpretation is based on “traffic light” conception. Green light allows continuing rope operation; yellow light means defects reached 70% of discard riteria, and red light alerts that rope may no longer be used. Following criteria are used to discard rope – number of broken wires along lay length and loss of metallic cross section area in percentage. INTROS-AUTO stores detailed data, which can be downloaded and interpreted in regular manner.
The instrument consists of magnetic head and control and display unit connected with cable up to 80 m length. Magnetic head has strong permanent magnets, and measuring systems is equipped with Hall Effect sensors and coils. Optionally odometer can be fixed on the magnetic head. Control and display unit is powered with DC 12V, and has wireless connection with PC. INTROS-AUTO can be used for rope monitoring and implemented into hoisting controlling system. It has been proven as effective mean to inspect ropes at onshore drilling rigs. Intron Plus is now approaching similar conception to develop continuous wire rope monitoring systems (CWRMS) for high value subsea construction ropes. CWRMS can be installed on the rope in operation to collect data on request, it will have interface to PLC. CWRMS enables to extend rope life according to current technical condition, or to discard dangerous ropes to avoid losses.
INTROCON is designed to non-destructively inspect steel cords in conveyor belts for breakage, corrosion, check splicing areas that may not be revealed visually. Results obtained from inspection help making decision about technical condition of the belts, and so, prevent accidents and provide savings. The instrument can be used for inspection of conveyor belts during its manufacture or on-site, it requires no termination of production run. Typical industries where INTROCON can be used are mining, steel plants, power stations, seaports, etc.
INTROCON can be used for continuous monitoring technical condition of steel cord conveyor belts. INTROCON utilizes eddy-current method of operation and comprises battery powered data logger, scanner, and software WINTROCON. The scanner is recommended to install with a frame 10-20 mm above the belt surface nearby the drum. To avoid damage of the scanner by bulky material running with the belt, the scanner is fixed with spring system. Data logger is connected to the scanner with the cable and shows inspection data on 2 LED displays, simultaneously storing data for further downloading.